Metallic carboxylate composition for forming thermoparticulating coating

ABSTRACT

A composition is disclosed of metallic carboxylate, a resinous carrier, and a solvent. The composition is applied to a portion of an electrical apparatus which is exposed to a gas stream. The solvent in the composition is evaporated to produce a thermoparticulating coating. When the electrical apparatus overheats the metallic carboxylate in the coating forms particles in the gas stream which are detected by a monitor.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is related to application Ser. No. 426,391, filed Dec. 19, 1973, by Emil M. Fort, Thomas D. Kaczmarek, and David Colin Phillips, entitled "Sampling System For Power Generators," now U.S. Pat. No. 3,972,225.

This application is also related to application Ser. No. 568,222, filed Apr. 15, 1975, by J. D. B. Smith, J. F. Meier, and D. C. Phillips, entitled "Blocked Isocyanate Composition For Forming Thermoparticulating Coating," now U.S. Pat. No. 4,056,005.

This application is related to application Ser. No. 568,219, filed Apr. 15, 1975, by J. D. B. Smith and D. C. Phillips, entitled "Malonic Acid Derivative Composition For Forming Thermoparticulating Coating," now U.S. Pat. No. 3,995,489.

This application is related to application Ser. No. 568,224, filed Apr. 15, 1975, by J. D. B. Smith and D. C. Phillips, entitled "Diazonium Salt Composition For Forming Thermoparticulating Coating," now U.S. Pat. No. 3,979,353.

This application is related to application Ser. No. 390,284, filed Aug. 21, 1973 by J. D. B. Smith et al., entitled "Composition For Forming Thermoparticulating Coating Which Protects Electrical Apparatus," now U.S. Pat. No. 3,973,438.

This application is related to application Ser. No. 568,221, filed Apr. 15, 1975, by J. D. B. Smith et al., entitled "Metal Acetyl Acetonate Composition For Forming Thermoparticulating Coating," now U.S. Pat. No. 3,973,439.

This application is related to application Ser. No. 568,223, filed Apr. 15, 1975, by J. D. B. Smith, D. C. Phillips, and K. W. Grossett, entitled "Grease Thermoparticulating Coating," now U.S. Pat. No. 3,955,417.

This application is related to application Ser. No. 568,218, filed Apr. 15, 1975, by D. C. Phillips, W. M. Hickam, and J. D. B. Smith, entitled "Multiple Signal Thermoparticulating Coating."

BACKGROUND OF THE INVENTION

Electrical apparatus, such as motors and turbine generators, occasionally overheat due to shorts or other malfunctions. The longer the overheating continues the more damage is done to the apparatus. A malfunction detected immediately may mean only a quick repair but if the overheating continues, the entire machine may be damaged.

Large rotating electrical apparatus is usually cooled with a hydrogen gas stream. The organic compounds in the apparatus are first to be affected by the overheating and they decompose to form particles which enter the gas stream. Monitors then detect particles in the gas stream and sound a warning or shut down the apparatus when too many particles are detected.

Descriptions of such monitors and how they function may be found in U.S. Pat. No. 3,427,880 entitled "Overheating Detector For Gas Cooled Electrical Machine" and in U.S. Pat. No. 3,573,460 entitled "Ion Chamber For Submicron Particles." Another monitor, "The Condensation Nuclei Detector," is described by F. W. VanLuik, Jr. and R. E. Rippere in an article entitled "Condensation Nuclei, A New Technique For Gas Analysis," in Analytical Chemistry 34,1617 (1962) and by G. F. Skala, in an article entitled "A New Instrument For The Continuous Detection of Condensation Nuclei," in Analytical Chemistry 35,702 (1963).

As U.S. Pat. Nos. 3,427,880 and 3,807,218 suggest, special coatings may be applied to the apparatus which decompose and form detectable particles at a lower temperature than the usual organic compounds found in the apparatus. For example, those patents mention polyalphamethylstyrene, polystyrene, polymethyl methacrylate, and cellulose propionate which decompose to form particles at 230° to 340° C. Unfortunately, since these machines normally operate at about 50° to 100° C, they may be severely damaged by the time the temperature reaches 230° to 340° C.

Efforts to identify materials which will decompose to form detectable particles (i.e., thermoparticulate) at temperatures closer to the operating temperature of the machine have met with several difficulties. Many compounds, such as maleic acid, fumaric acid, and polyacrylic acid, do not decompose below 190° C. Others such as acetic acid, are liquids which boil and therefore are unsuitable. Some compounds, such as oxalic acid, decompose at a low temperature but the decomposition products do not include detectable particles. Compounds such as 1,2-diformylhydrazine have some of the desirable properties but cannot withstand several years operation at 50° to 100° C. A few compounds contain toxic or corrosive substances in their decomposition products which may render them unsuitable.

SUMMARY OF THE INVENTION

We have found that metallic carboxylates can be used in a composition to form a thermoparticulating coating. The coating can be made compatible with the other organic compounds in the apparatus. The coating is very stable and can withstand several years operation at 60° or 80° C. (depending on the particular metallic carboxylate used) without decomposing, yet still produce detectable particles when the temperature reaches about 150° to 190° C. (depending on the particular metallic carboxylate used). Also, when the coating is heated to about the thermoparticulating temperature of the coating it blisters and becomes a very dark brown or black color which is a considerable aid in locating the malfunction.

We have also found that the thermoparticulation products of metallic carboxylates give strong signals in the monitor and very distinctive "fingerprints" in a mass spectrometer. Distinctive fingerprints are useful because they enable one to quickly identify the compound which thermoparticulates, and since the exact area in the generator where that compound was used is known, the area of overheating is pinpointed.

DESCRIPTION OF THE INVENTION

A composition is prepared of a metallic acetates in a solution of a resinous carrier. The carboxylate may be dispersed if it is insoluble in the solvent (e.g., toluene) or it may be in solution if it is soluble in the solvent (e.g., ethyl alcohol or diethyl ether). Dispersions are preferred as they produce much more particulation than do solutions. A particle size of the dispersed metallic carboxylate of about 25 to about 1000 microns is suitable.

The composition may be prepared by simply mixing the ingredients, but it is preferable to mix the drier, resinous carrier, and solvent first and then add the metallic carboxylates to prevent the occlusion of the drier in the metallic carboxylate and thereby obtain a more homogeneous dispersion of the metallic carboxylate.

A suitable composition is a resinous carrier, about 20 to about 250 phr (parts by weight per hundred parts of resinous carrier) of metallic carboxylate, to about 25 to about 75% (by weight based on the resinous carrier) of a solvent for the resinous carrier. If the amount of metallic carboxylate is less than about 20 phr, the quantity of particles given off during decomposition may be too low to be detected by presently-existing detectors. However, the construction of more sensitive detectors would permit a lower amount of metallic carboxylate. If the amount of metallic carboxylate exceeds about 250 phr, the composition is thick, difficult to apply, and does not bond well. The preferred amount of metallic carboxylate, which generally gives the best results, is about 40 to about 60 phr. If the amount of solvent is less than about 25%, the composition is generally too viscous to apply easily and if the amount of solvent is greater than about 75%, the composition is unnecessarily dilute and the coating may be too thin to produce an adequate number of particles during decomposition, at least while the malfunction is highly localized. Best results are usually obtained with about 45 to about 55% solvent.

The composition also preferably contains about 0.1 to about 3 phr of a drier when the resinous carrier is an epoxy resin or similar resin to promote its room temperature cure. Lead naphthenate or cobalt naphthenate is preferred although stannous octoate, zinc stearate, etc. could also be used. Resins such as polyesters may also require the presence of an organic peroxide as is known in the art. Mixtures of various resins, solvents, or driers are also contemplated.

The thermoparticulating compounds of this invention are metallic carboxylates which decompose between about 60° and about 200° C. and produce particles larger than about 25A, the smallest particle size that can be detected with presently-existing monitors. Specifically, suitable metallic carboxylates have the general formula ##STR1## where each R is independently selected from hydrogen alkyl to C₂₀, cycloalkyl to C₂₀, alkylaryl to C₂₀, arylalkyl to C₂₀, aryl, and heterocyclic. Preferably each R is butyl or phenyl as these compounds are easier to synthesize. The "m" in the formula is the number of R groups; it may be 0 to 4 but is preferably 3 as those compounds are easier to make. Each R' is independently selected from alkyl to C₇ ; preferably, R' is --CH₃ as those compounds are easier to make. The M element in the formula may be Cu, Pb, Sn, or Hg but is preferably Pb as lead compounds have lower thermoparticulating temperatures. The "n" in the formula is the number of charges on the M ion and therefore the number of carboxylate groups, and may be 1, 2, 3, or 4 but is preferably 2 as those compounds are more readily available. The "x" in the formula is the amount of water of hydration and may be 0 to 10 but is preferably 0 to 2. Examples of suitable metallic carboxylates are given in the examples.

The resinous carrier performs the function of bonding the metallic carboxylate to the apparatus since a coating of metallic carboxylate by itself does not adhere well. The resinous carrier should be compatible with the other resins used in the apparatus and therefore it is usually advantageous to use the same resin used elsewhere. The resinous carrier is curable at 60° C. and is preferably air dryable since it cannot be easily cured in place with heat. Also, it should be stable after curing for several years at 60° C. The resin must be unreactive with the metallic carboxylate or otherwise suitable thermoparticulation will not occur. The metallic carboxylate and the resin form a mixture and the metallic carboxylate does not catalyze the cure of the resin. Epoxy resins are preferred as they are usually used elsewhere in the apparatus, but polyesters, silicone rubber, polystyrene, etc. could also be used.

The solvent for the resinous carrier depends on the particular resinous carrier used. Toluene, xylene, benzene, methyl ethyl ketone, ethyl alcohol, diethyl ether, acetone, cellosolve, etc. are common solvents that may be used. Toluene is preferred as it is inexpensive and dissolves most resins.

The composition is applied to portions of the electrical apparatus which are exposed to the gas stream. The coating does not function as insulation and is usually applied on top of insulation, but it can also be applied to conductors. The application may be made by brushing, spraying, dipping, grease gun, troweling or other techniques. A suitable coating thickness (after drying) is about one-sixteenth to about one-half inch. The dispersed particles of metallic carboxylate should not be covered with excessive resinous carrier as that may prevent the decomposition particles from escaping into the gas stream. After evaporation of the solvent and room temperature cure of the resinous carrier, if necessary, the apparatus is ready to be operated. When thermoparticulation and the resulting alarm occur, a sample of the gas stream can be collected and analyzed. Since different metallic carboxylates and other thermoparticulating compounds can be used in different areas of the apparatus and their thermoparticulation products are different, analysis of the sample can pinpoint the location of the overheating.

The compositions of this invention are useful in areas of generators which are not subject to temperatures much in excess of 60° or 80° C. (depending on the particular metallic carboxylate used). Such areas include the outside surface of the stator windings at the exciter end of a 2-pole, gas-cooled machine with radial gas flow (i.e., at the "cool" end), the outside surface of the stator windings at the exciter end of a water-cooled, 4-pole machine with axial core ventilation, and on the cool end of the stator coil of a 4-pole, gas-cooled machine with axial core ventilation.

The following examples further illustrates this invention.

EXAMPLE 1

The following composition was prepared using various metallic carboxylates:

    ______________________________________                                                             Parts by Weight                                            ______________________________________                                         Metallic carboxylate  100                                                      Epoxy resin, 50% solids in                                                     toluene, made from 200 pbw                                                     (parts by weight) linseed                                                      fatty acids, 200 pbw styrene, -and 300 pbw diglycidyl ether                    of Bisphenol A, sold by                                                        Westinghouse Electric Cor-                                                     poration as "B-276" Varnish                                                    (See Example 1 of U.S. Pat.                                                    2,909,497 for detailed des-                                                    cription)             100                                                       6% solution in low boiling                                                    hydrocarbons of cobalt                                                         naphthenate           1.0                                                      24% solution in low boiling                                                    hydrocarbons of lead naphthenate                                                                     0.25                                                     ______________________________________                                    

The cobalt and lead naphthenate solutions were added to the epoxy resin prior to the addition of the metallic carboxylate.

Samples were prepared by brushing the above composition onto 3 inch by 1 inch aluminum sheets one-sixteenth to one-fourth inches thick. The samples were dried overnight at 60° C. to form coatings one-fourth inches thick, then placed in a forced-air oven at 60° or 80° C for various periods to determine if they were stable and would function after aging.

The samples were placed one at a time in a stainless steel boat within a 1 inch o.d. stainless steel tube. Hydrogen was passed over the samples at flow rate of 6 liters/min. A phase-controlled temperature regulator and programmer controlled the temperature in the boat and the temperature in the boat was measured by mounting a hot junction chromel-alumel thermocouple within a small hole in the boat. The output of the thermocouple and the detector were monitored on a two-pen potentiostatic recorder. A 6° C./min. heating rate was maintained in each experiment after the insertion of the sample in the boat. The "alarm" temperature at which considerable particulation occurred was taken from the chart; this corresponded to a 50% decrease in the initial ion current of the Generator Condition Monitor (usually 0.8 to 0.4 mA). The temperature where thermoparticulation began was also noted (i.e., the "threshold" temperature). These two temperatures enabled a "thermoparticulation temperature range" to be recorded for each sample (i.e., the organic particulation temperature range, OPTR).

The following table gives the results:

    ______________________________________                                                        Aging         OPTR                                              Acetate        Condition     (° C)                                      ______________________________________                                         Triphenyltin Acetate                                                                          44 days at 60° C                                                                      153-161                                                          66 days at 60° C                                                                      154-160                                                          19 months at 60° C                                                                    158-162                                                          15 months at 80° C                                                                    178-181                                                          17 months at 80° C                                                                    179-185                                           Tributyltin Acetate                                                                           3 days at 60° C                                                                       > 190                                             Tributyllead Acetate                                                                          6 days at 60° C                                                                       128-132                                           Triphenyllead Acetate                                                                         6 days at 60° C                                                                       167-182                                                          16 months at 60° C                                                                    159-166                                           Cobalt Acetate*                                                                               16 hours at 60° C                                                                     > 190                                             Cadmium Acetate*                                                                              16 hours at 60° C                                                                     > 190                                             Copper Acetate 16 hours at 60° C                                                                     171-174                                                          8-1/4 months at 60° C                                                                 174-181                                           Indium Acetate*                                                                               16 hours at 60° C                                                                     > 190                                             Iron Acetate*  16 hours at 60° C                                                                     > 190                                             Lead Acetate   16 hours at 60° C                                                                     165-186                                                          110 days at 80° C                                                                     164-179                                                          4 months at 80° C                                                                     160-174                                           Mercuric Acetate                                                                              16 hours at 60° C                                                                     158-161                                                          4 months at 80° C                                                                     163-178                                           Magnesium Acetate                                                                             16 hours at 60° C                                                                     > 190                                             Lithium Acetate*                                                                              16 hours at 60° C                                                                     > 190                                             Manganese Acetate*                                                                            16 hours at 60° C                                                                     > 190                                             Nickel Acetate*                                                                               16 hours at 60° C                                                                     > 190                                             Dibutyl tin di-2-ethyl                                                         hexate         280 days at 80° C                                                                     167-172                                           Uranyl Acetate*                                                                               16 hours at 60° C                                                                     > 190                                             ______________________________________                                          *Very weak signals show at about 100 to 120° C.                   

The above table shows that the cobalt, cadmium, indium, iron, magnesium, lithium, manganese, nickel, and uranium compounds were unsatisfactory.

EXAMPLE 2

A composition containing triphenyltin acetate prepared as in Example 1 was brushed onto copper rectangular blocks (4 × 2-1/4 × 1-1/2 inches). The coating was allowed to dry overnight at 60° to 80° C.; total coating build was approximately 10 mils over an area of 31 square inches (end plates not covered).

The block contained two 650 watt heaters drilled into the copper core; the heaters were connected in parallel (two exit leads). The copper block was also equipped with two thermocouples. The block was connected to separate inspection plates in a large generator (four sides of block in hydrogen flow); each block being approximately 1/2 inch from the outer surface of the generator. The generator was 112 inches in diameter by 245 inches long, 2-poles, 26KV(98) MVA.

In the tests, the coated blocks were externally heated by a source of electrical power. The rate of rise of temperature was controlled to 5° C/minute and the hydrogen was monitored for particulate matter by means of an Environment One Generator Condition Monitor.

The following table gives the results:

    ______________________________________                                                          Monitor                                                       Monitor          Flow                  Gas                                     Alarm    Time    (meter)               Temp-                                   Temperature                                                                             of Run  reading  Pressure                                                                              Speed erature                                 ______________________________________                                         155      15 min. 10.2     30 psi 2800  31° C                                                             rpm                                           ______________________________________                                     

We claim:
 1. A composition curable at room temperature consisting essentially of about 20 to about 250 phr of at least one metallic carboxylate and a solution of an air-dryable epoxy resinous carrier stable at 60° C when cured, and unreactive with said metallic carboxylate, said metallic carboxylate having the general formula ##STR2## where each R is independently selected from the group consisting of alkyl to C₂₀, and aryl, each R' is independently selected from alkyl to C₆, M is copper, lead, tin, or mercury, m is 0 to 4, n is 1 to 4, and x 15 0 to
 10. 2. A composition according to claim 1 wherein each R is independently selected from butyl and phenyl.
 3. A composition according to claim 1 wherein M is lead.
 4. A composition according to claim 3 wherein m is 3, n is 2, x is 0 to 2, and R' is --CH₃.
 5. A composition according to claim 1 wherein the amount of the solvent in said solution is about 25 to about 75% (by weight based on said resinous carrier).
 6. A composition according to claim 5 wherein the amount of said carboxylate is about 40 to about 60 phr and the amount of said solvent is about 45 to about 55% (by weight based on said resinous carrier).
 7. A composition according to claim 1 which includes about 0.1 to about 3 phr of a drier for said epoxy resin.
 8. A composition according to claim 7 which is prepared by first mixing said solution of resinous carrier and said drier and then mixing in said carboxylate.
 9. A composition according to claim 1 wherein the solvent in said solution is toluene.
 10. A composition according to claim 1 wherein said carboxylate is dispersed in said solution.
 11. A method of protecting electrical apparatus from damage due to overheating and for thereafter determining the location of said overheating, said apparatus including a gas stream and a monitor for detecting particles in said gas stream and for emitting a signal when said particles are detected comprising:(A) preparing a thermoparticulating composition according to claim 1; (B) applying said composition to said electrical apparatus at positions exposed to said gas stream; (C) evaporating said solvent; and (D) monitoring said gas stream for the presence of thermoparticulated particles therein.
 12. A method according to claim 11 including the additional last step of inspecting said applied composition visually for blistered and darkened areas, after a signal has been emitted, to locate the area of overheating.
 13. A method according to claim 12 including the additional last steps of collecting a sample of said gas stream after a signal has been emitted, and analyzing said sample.
 14. A thermoparticulating coating consisting essentially of a solid layer of a room-temperature air-dryed epoxy resinous carrier stable at 60° C containing about 20 to about 250 phr of a metallic carboxylate having the general formula ##STR3## where each R is independently selected from the group consisting of alkyl to C₂₀, and aryl, each R' is independently selected from alkyl to C₆, M is copper, lead, tin, or mercury, m is 0 to 4, n is 1 to 4, and x is 0 to
 10. 15. A coating according to claim 14 which is about one-sixteenth to about one-half inches thick.
 16. A thermal detection system for electrical apparatus cooled by a gas stream, comprising a thermoparticulating coating on a portion of said electrical apparatus exposed to said gas stream and a monitor for detecting the presence of thermoparticulated particles in said gas stream, said coating comprising a solid layer of a room temperature air-dryed epoxy or polyester resinous carrier containing about 20 to about 250 phr of a metallic carboxylate having the general formula ##STR4## where each R is independently selected from the group consisting of hydrogen, alkyl to C₂₀, cycloalkyl to C₂₀, alkylaryl to C₂₀, arylalkyl to C₂₀, aryl, and heterocyclic, each R' is independently selected from alkyl to C₆, M is copper, lead, tin, or mercury, m is 0 to 4, n is 1 to 4, and x is 0 to
 10. 17. A method according to claim 11 wherein each R is independently selected from butyl and phenyl.
 18. A method according to claim 11 wherein M is lead.
 19. A method according to claim 18 wherein m is 3, n is 2, x is 0 to 2, and R' is --CH₃.
 20. A method according to claim 11 wherein the amount of the solvent in said solution is about 25 to about 75% (by weight based on said resinous carrier).
 21. A method according to claim 20 wherein the amount of said carboxylate is about 40 to about 60 phr and the amount of said solvent is about 45 to about 55% (by weight based on said resinous carrier).
 22. A method according to claim 11 wherein it includes about 0.1 to about 3 phr of a drier for said epoxy resin.
 23. A method according to claim 22 which is prepared by first mixing said solution of resinous carrier and said drier and then mixing in said carboxylate.
 24. A method according to claim 11 wherein the solvent in said solution is toluene.
 25. A method according to claim 11 wherein said carboxylate is dispersed in said solution.
 26. A thermal detection system according to claim 16 wherein each R is independently selected from butyl and phenyl.
 27. A thermal detection system according to claim 16 wherein M is lead.
 28. A thermal detection system according to claim 27 wherein m is 3, n is 2, x is 0 to 2, and R' is --CH₃.
 29. A thermal detection system according to claim 16 wherein the amount of the solvent in said solvent is about 25 to about 75% (by weight based on said resinous carrier).
 30. A thermal detection system according to claim 29 wherein the amount of said carboxylate is about 40 to about 60 phr and the amount of said solvent is about 45 to about 55% (by weight based on said resinous carrier).
 31. A thermal detection system according to claim 16 wherein said resinous carrier is an epoxy resin.
 32. A thermal detection system according to claim 16 wherein it includes about 0.1 to about 3 phr of a drier for said epoxy resin.
 33. A thermal detection system according to claim 32 which is prepared by first mixing said solution of resinous carrier and said drier and then mixing in said carboxylate.
 34. A thermal detection system according to claim 16 wherein the solvent in said solution is toluene.
 35. A thermal detection system according to claim 16 wherein said carboxylate is dispersed in said solution. 